The Mine-to-Process integration and optimisation methodology utilises Hatch’s expertise, industry validated modelling and simulation tools, and extensive database to maximise the profitability of the entire operation (from mine to plant) with minimal capital expenditure. This holistic approach has delivered throughput and efficiency benefits as well as cost reduction to many operations worldwide including Grange Resources’ Tasmanian based Savage River operation. This paper details the integrated Mine-to-Process optimisation completed at Grange Resources Savage River and how the mechanistic, mathematical models developed during the project have been continually leveraged to support site’s successive optimisation and engineering design studies. During the project, site-specific mechanistic models of the mine and plant (blast fragmentation, crushing, grinding, screening, cyclones, magnetic separation) were developed and calibrated based on historical data, audits and surveys conducted by Savage River and Hatch personnel. The models were used to simulate and determine the optimal strategy for achieving the objectives of maintaining concentrate production rates with the lower Fe feed grades expected towards the mine’s end of life, improve final product quality and reduce costs. Several opportunities to increase the comminution circuit throughput were identified and evaluated and as a result Savage River is now in the process of upgrading the pebble crushers in the primary grinding circuit and implementing several other recommendations. Additionally, Savage River is now also actively evaluating the upgrade of its secondary grinding circuit which was identified to be lacking capacity. The site-specific models were again used in subsequent studies focused on the effects of transitioning from the current open pit to a block cave mining method. This study highlighted how ore characteristics and the Run-of-Mine (ROM) fragmentation from the block cave would differ from the current open pit operation and how it would likely evolve through the life-of-mine and impact the processing plant. The models were used to evaluate the effects of these changes on the performance of the comminution and concentration circuits and to identify opportunities to maintain concentrate production. Additionally, several other opportunities highlighted during the Mine-to Process project were revisited and refreshed based on the updated information of Savage River’s forward workplan.